Delivery vehicle

ABSTRACT

The present invention provides a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

PRIORITY CLAIM

The present application is a National Phase entry of PCT Application No. PCT/GB2019/051083, filed Apr. 16, 2019, which claims priority from GB Patent Application No. 1806245.5, filed Apr. 17, 2018, each of which is hereby fully incorporated herein by reference.

FIELD OF THE INVENTION

The present disclosure relates to a delivery vehicle, containers in which are contained the delivery vehicle, and to electronic aerosol provision systems such as electronic aerosol delivery systems (e.g. e-cigarettes) incorporating said product.

BACKGROUND TO THE INVENTION

Electronic vapor provision systems such as e-cigarettes generally contain a reservoir of liquid which is to be vaporized, typically containing nicotine. When a user inhales on the device, a heater is activated to vaporize a small amount of liquid, which is therefore inhaled by the user.

The use of e-cigarettes in the UK has grown rapidly, and it has been estimated that there are now almost three million people using them in the UK.

Current vaping products use liquids which are wicked to a heater that generates an aerosol. The aerosol is inhaled by the user and provides a sensory experience similar to that of smoking tobacco. The aerosol may also be used to deliver nicotine and/or flavor. Some vaping products deliver nicotine but do not contain flavor. Some deliver flavor but no nicotine. Some deliver both flavor and nicotine. Current e-cigarette formulations typically utilize glycerol and/or propylene glycol as the liquid. In the flavor delivering systems it is known that a material can be used to hold flavor or another functionalizing component for delivering a sensory effect in the aerosol to be delivered. For example, in US 2005/0172976 flavor or another functionalizing component can be held in a flavor release additive such as a bead, film or inclusion complex. The materials taught as being suitable for encapsulating the flavor include various known materials and are designed such that they release their flavor at a given temperature. However, materials which have high loadings of flavor or another functionalizing component may suffer from depletion of the flavor or another functionalizing component during storage.

SUMMARY OF THE INVENTION

In one aspect there is provided a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

The present invention further provides a contained delivery vehicle for functionalizing an aerosol, the contained delivery vehicle comprising

(a) a container; and

(b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

The present invention further provides an aerosolizable product comprising

(a) an aerosol forming material; and

(b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

The present invention further provides a process for forming a functionalized aerosol, the process comprising

(a) providing a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate; and

(b) placing an aerosol in proximity with the delivery vehicle.

The present invention further provides an electronic aerosol provision system comprising:

(a) an aerosol generation device; and

(b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will now be described in further detail by way of example only with reference to the accompanying figures in which:

FIG. 1 shows a graph of the loading loss over time at various temperatures of a control sample.

FIG. 2 shows a graph of the loading loss over time at various temperatures of Sample 1 having an initial 70% fragrance/flavor of cherry by weight, according to certain embodiments of the present invention.

FIG. 3 shows a graph of the loading loss over time at various temperatures of Sample 2 having an initial 70% fragrance/flavor of peppermint/menthol by weight, according to certain embodiments of the present invention.

DETAILED DESCRIPTION

As discussed herein, the present invention provides a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

We have found that by use of delivery vehicle comprising a porous substrate material comprising at least one porous thermoplastic polymer which has a functionalizing component loading capacity of at least 30% w/w, appreciable amounts of functionalizing component may be held within the thermoplastic polymer yet when the delivery vehicle is positioned within the airflow path of an aerosol which is to be functionalized the pressure drop across the delivery vehicle can be reduced. This is advantageous as it is possible for the user to add the delivery vehicle to an aerosol delivery device in order to functionalize the aerosol without affecting (or hardly affecting) the pressure drop across the delivery vehicle. Since users of aerosol delivery devices, such as e-cigarettes, are sensitive to the pressure drop across the device during an inhalation, it is advantageous to provide a delivery vehicle which does not lead to a significant (if any) additional pressure drop when placed in the airflow path of the aerosol.

For ease of reference, these and further aspects of the present invention are now discussed under appropriate section headings. However, the teachings under each section are not necessarily limited to each particular section.

Porous Substrate Material

As discussed herein the present invention provides a delivery vehicle having a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate.

The porous thermoplastic polymer may be any suitable thermoplastic polymer. In one aspect, the thermoplastic polymer is selected from acrylonitrile butadiene styrene, natural rubber, nylon 6, polyamide, polyamideimide, polyarylate, polycarbonate, polydimethyl siloxane, polyetheretherketone, polyetherimide, polyethersulphone, polyethylene, polyethylene terephthalate, polymethylmethacrylate, polyoxymethylene, polyphenylene sulphide, polypropylene, polystyrene, polysulphone, polytetrafluoroethylene, polyvinylchloride, and mixtures thereof. In one aspect, the thermoplastic polymer is at least polypropylene. Suitable polymers, such as suitable polypropylene, may be delivered in any suitable physical form, for example they may be delivered in the form of pellets, powders, granules or films. Even when loaded with the functionalizing component as described herein the thermoplastic polymer in the form of powder, pellets or granules remain dry and free flowing making them convenient for dosing and handling.

In one aspect the delivery vehicle comprises a first porous thermoplastic polymer and a second porous thermoplastic polymer, wherein the first thermoplastic polymer and the second thermoplastic polymer are different from each other. In one aspect, the first thermoplastic polymer is selected from acrylonitrile butadiene styrene, natural rubber, nylon 6, polyamide, polyamideimide, polyarylate, polycarbonate, polydimethyl siloxane, polyetheretherketone, polyetherimide, polyethersulphone, polyethylene, polyethylene terephthalate, polymethylmethacrylate, polyoxymethylene, polyphenylene sulphide, polypropylene, polystyrene, polysulphone, polytetrafluoroethylene, polyvinylchloride, and mixtures thereof. In one aspect, the first thermoplastic polymer is at least polypropylene. In one aspect, the second thermoplastic polymer is selected from acrylonitrile butadiene styrene, natural rubber, nylon 6, polyamide, polyamideimide, polyarylate, polycarbonate, polydimethyl siloxane, polyetheretherketone, polyetherimide, polyethersulphone, polyethylene, polyethylene terephthalate, polymethylmethacrylate, polyoxymethylene, polyphenylene sulphide, polypropylene, polystyrene, polysulphone, polytetrafluoroethylene, polyvinylchloride, and mixtures thereof. In one aspect, the second thermoplastic polymer is at least polypropylene.

The at least one porous thermoplastic polymer of the present delivery vehicle may have a nominal pore size of from 0.01 to 1 μm. In one aspect the porous thermoplastic polymer present in the delivery system consists of porous thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm.

The porous substrate material may be formed wholly or in part from thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 10 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 20 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 30 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 40 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 50 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 60 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 70 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 80 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 90 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 95 wt. % based on the porous substrate material. In one aspect thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm is present in an amount of at least 99 wt. % based on the porous substrate material. In one aspect the porous substrate material consists essentially of thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm. In one aspect the porous substrate material consists of thermoplastic polymer having a nominal pore size of from 0.01 to 1 μm.

In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.9 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.8 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.7 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.6 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.5 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.4 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.01 to 0.3 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.05 to 0.3 μm. In one aspect the at least one thermoplastic polymer has a nominal pore size of from 0.1 to 0.3 μm.

In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.9 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.8 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.7 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.6 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.5 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.4 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.01 to 0.3 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.05 to 0.3 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having a nominal pore size of from 0.1 to 0.3 μm.

In one embodiment, the at least one porous thermoplastic polymer of the present delivery vehicle may have an average pore size of from 0.01 to 1 μm. Suitable methods for determining the average pore size include via scanning electron microscope.

In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.9 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.8 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.7 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.6 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.5 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.4 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.01 to 0.3 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.05 to 0.3 μm. In one aspect the at least one thermoplastic polymer has an average pore size of from 0.1 to 0.3 μm.

In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.9 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.8 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.7 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.6 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.5 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.4 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.01 to 0.3 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.05 to 0.3 μm. In one aspect thermoplastic polymer present in the delivery system consists of thermoplastic polymer having an average pore size of from 0.1 to 0.3 μm.

The porous substrate material may be present in any suitable amount to provide the desired aim of functionalizing an aerosol. In one aspect, the porous substrate material is present in an amount of at least 0.2 g. In one aspect, the porous substrate material is present in an amount of at least 0.3 g. In one aspect, the porous substrate material is present in an amount of at least 0.4 g. In one aspect, the porous substrate material is present in an amount of at least 0.5 g. In one aspect, the porous substrate material is present in an amount of at least 0.6 g. In one aspect, the porous substrate material is present in an amount of at least 0.7 g. In one aspect, the porous substrate material is present in an amount of at least 0.8 g. In one aspect, the porous substrate material is present in an amount of at least 0.9 g. In one aspect, the porous substrate material is present in an amount of at least 1.0 g. In one aspect, the porous substrate material is present in an amount of at least 1.5 g. In one aspect, the porous substrate material is present in an amount of at least 2.0 g.

In one aspect, the porous substrate material is present in an amount of up to 10.0 g. In one aspect, the porous substrate material is present in an amount of up to 9.0 g. In one aspect, the porous substrate material is present in an amount of up to 8.0 g. In one aspect, the porous substrate material is present in an amount of up to 7.0 g. In one aspect, the porous substrate material is present in an amount of up to 6.0 g. In one aspect, the porous substrate material is present in an amount of up to 5.0 g. In one aspect, the porous substrate material is present in an amount of up to 4.0 g. In one aspect, the porous substrate material is present in an amount of up to 3.0 g. In one aspect, the porous substrate material is present in an amount of up to 2.9 g. In one aspect, the porous substrate material is present in an amount of up to 2.8 g. In one aspect, the porous substrate material is present in an amount of up to 2.7 g. In one aspect, the porous substrate material is present in an amount of up to 2.6 g. In one aspect, the porous substrate material is present in an amount of up to 2.5 g.

Functionalizing Component

The functionalizing component may be any material which modifies the nature of the aerosol with which it is contacted. In one aspect, the at least one functionalizing component may be selected from flavor components, protonating components, active components and mixtures thereof. In one aspect the at least one functionalizing component is at least one flavor component. A flavored component is a material which imparts a flavor to the aerosol. In one aspect the at least one flavor component is selected from the group consisting of (4-(para-) methoxyphenyl)-2-butanone, vanillin, γ-undecalactone, menthone, 5-propenyl guaethol, menthol, para-mentha-8-thiol-3-one and mixtures thereof. In one aspect, the at least one flavor component is at least menthol.

The functionalizing component may be solid or liquid. In one aspect the functionalizing component is a solid at temperature of 40° C. In one aspect the functionalizing component is a solid at temperature of 60° C. In one aspect, the functionalizing component is a powder, such as a free flowing powder.

The at least one functionalizing component may be present in any suitable amount to provide the desired aim of functionalizing an aerosol. In one aspect the at least one functionalizing component is present in an amount of at least 1 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 2 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 3 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 4 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 5 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 10 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 15 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 20 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 25 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 30 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 40 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 50 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 60 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 70 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 80 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of at least 90 wt. % based on the porous substrate.

In one aspect the at least one functionalizing component is present in an amount of from 1 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 2 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 3 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 4 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 5 to 90 wt. % based on porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 10 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 20 to 90 wt. % based on the porous substrate. In one aspect the at least one functionalizing component is present in an amount of from 20 to 90 wt. % based on the porous substrate.

In one aspect the formulation comprises the functionalizing component and a carrier. The carrier may be selected from water, polyhydric alcohols, such as glycerol, propylene glycol and triethylene glycol, for example, or esters such as triethyl citrate or triacetin, or high boiling point hydrocarbons, or non-polyols, such as glycols, sorbitol or lactic acid, for example. The carrier may be selected from polyhydric alcohols, such as glycerol, propylene glycol and triethylene glycol, for example, or esters such as triethyl citrate or triacetin, or high boiling point hydrocarbons, or non-polyols, such as glycols, sorbitol or lactic acid, for example. In one aspect, the carrier is selected from polyhydric alcohols (such as glycerol, propylene glycol and triethylene glycol), esters (such as triethyl citrate and triacetin), high boiling point hydrocarbons, non-polyols (such as glycols, sorbitol and lactic acid), and mixtures thereof.

The carrier may be selected from water, triethylene glycol, triethyl citrate, triacetin, glycols, sorbitol, lactic acid, glycerol, propylene glycol, and mixtures thereof. The carrier may be selected from triethylene glycol, triethyl citrate, triacetin, glycols, sorbitol, lactic acid, glycerol, propylene glycol, and mixtures thereof.

In one aspect, the carrier is selected from water, glycerol, propylene glycol, and mixtures thereof. In one aspect, the carrier is selected from glycerol, propylene glycol, and mixtures thereof. In one aspect, the carrier is a mixture of glycerol and propylene glycol.

The one or more carriers may be present in any suitable amount in the formulation depending on the functionalizing component. In one aspect the one or more carriers is present in a total amount of at least 1 wt. % based on the formulation. In one aspect the one or more carriers is present in a total amount of at least 2 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 5 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 10 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 20 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 30 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 40 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of at least 50 wt. % based on the formulation.

In one aspect the one or more carriers is present in a total amount of from 1 to 990 wt. % based on the formulation. In one aspect the one or more carriers is present in a total amount of from 2 to 50 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of from 5 to 50 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of from 10 to 50 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of from 20 to 50 wt. % based on the formulation. In one aspect the one or more carriers are present in a total amount of from 30 to 50 wt. % based on formulation.

As discussed herein, in one aspect the carrier is at least glycerol. The glycerol may be present in any suitable amount in the formulation. In one aspect the glycerol is present in a total amount of at least 1 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 2 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 5 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 10 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 20 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 30 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 40 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of at least 50 wt. % based on the formulation.

In one aspect the glycerol is present in a total amount of from 1 to 99 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 1 to 90 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 1 to 80 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 1 to 70 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 1 to 60 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 1 to 90 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 2 to 50 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 5 to 50 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 10 to 50 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 20 to 50 wt. % based on the formulation. In one aspect the glycerol is present in a total amount of from 30 to 50 wt. % based on the formulation.

As discussed herein, in one aspect the carrier is at least propylene glycol. The propylene glycol may be present in any suitable amount in the formulation. In one aspect the propylene glycol is present in a total amount of at least 1 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 2 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 5 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 10 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 20 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 30 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 40 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of at least 50 wt. % based on the formulation.

In one aspect the propylene glycol is present in a total amount of from 1 to 99 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 1 to 90 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 1 to 80 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 1 to 70 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 1 to 60 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 1 to 50 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 2 to 50 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 5 to 50 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 10 to 50 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 20 to 50 wt. % based on the formulation. In one aspect the propylene glycol is present in a total amount of from 30 to 50 wt. % based on the formulation.

As discussed herein, in one aspect the carrier is at least water. The water may be present in any suitable amount in the formulation. In one aspect the water is present in a total amount of at least 1 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 2 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 5 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 10 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 20 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 30 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 40 wt. % based on the formulation. In one aspect the water is present in a total amount of at least 50 wt. % based on the formulation.

In one aspect the water is present in a total amount of from 1 to 50 wt. % based on the formulation. In one aspect the water is present in a total amount of from 2 to 50 wt. % based on the formulation. In one aspect the water is present in a total amount of from 5 to 50 wt. % based on the formulation. In one aspect the water is present in a total amount of from 10 to 50 wt. % based on the formulation. In one aspect the water is present in a total amount of from 20 to 50 wt. % based on the formulation. In one aspect the water is present in a total amount of from 30 to 50 wt. % based on the formulation.

The porous thermoplastic polymer has a formulation loading capacity of at least 30 wt. % based on the porous substrate. In one aspect the porous thermoplastic polymer has a formulation loading capacity of at least 40 wt. % based on the porous substrate. In one aspect the porous thermoplastic polymer has a formulation loading capacity of at least 50 wt. % based on the porous substrate. In one aspect the porous thermoplastic polymer has a formulation loading capacity of at least 60 wt. % based on the porous substrate. In one aspect the porous thermoplastic polymer has a formulation loading capacity of at least 70 wt. % based on the porous substrate. In one aspect the porous thermoplastic polymer has a formulation loading capacity of at least 80 wt. % based on the porous substrate.

Aerosolizable Product

The delivery vehicle of the present invention may contain one or more further components, which may be present in the formulation, adhered to the porous substrate, or located elsewhere on the delivery vehicle. These components may be selected depending on the nature of the formulation. In one aspect, the delivery vehicle further comprises an active agent. By “active agent” it is meant an agent which has a biological effect on a subject when the vapor is inhaled. The one or more active agents may be selected from nicotine, botanicals, and mixtures thereof. The one or more active agents may be of synthetic or natural origin. The active could be an extract from a botanical, such as from a plant in the tobacco family. An example active is nicotine.

In one aspect, the active agent is at least nicotine. Nicotine may be provided at any suitable amount depending on the desired dosage to be inhaled by the user. In one aspect nicotine is present in an amount of no greater than 6 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 6 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 6 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 6 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1.8 to 6 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 5 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 5 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 5 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1.8 to 5 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of no greater than 4 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 4 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 4 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 4 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1.8 to 4 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of no greater than 3 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 3 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 3 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 3 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1.8 to 3 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of no greater than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of no greater than 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.5 to 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.5 to 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of less than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of less than 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to less than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.4 to less than 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.5 to less than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.5 to less than 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to less than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 0.8 to less than 1.8 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to less than 1.9 wt % based on the total weight of the delivery vehicle. In one aspect nicotine is present in an amount of from 1 to less than 1.8 wt % based on the total weight of the delivery vehicle.

Delivery Vehicle

As explained above, the delivery vehicle generally comprises both the porous substrate and the formulation contained within the porous substrate. In this regard the porous substrate is generally held within a housing having a connection end and a mouthpiece end. The connection end attaches to an opening in the aerosol delivery device, and the mouthpiece end contains an outlet for the inhalation of aerosol that has been functionalized.

In one aspect, the housing contains a cavity within which the porous substrate is retained. The porous substrate may be retained within the cavity so as to have a minimal influence on the pressure drop across the delivery vehicle. In one aspect, the porous substrate is retained within the cavity of the delivery vehicle such that the increase in pressure drop across the delivery vehicle relative to the delivery vehicle without any porous substrate is less than 20 mmH₂O. In one aspect, the porous substrate is retained within the cavity of the delivery vehicle such that the increase in pressure drop across the delivery vehicle relative to the delivery vehicle without any porous substrate is less than 15 mmH₂O. In one aspect, the porous substrate is retained within the cavity of the delivery vehicle such that the increase in pressure drop across the delivery vehicle relative to the delivery vehicle without any porous substrate is less than 10 mmH₂O. In one aspect, the porous substrate is retained within the cavity of the delivery vehicle such that the increase in pressure drop across the delivery vehicle relative to the delivery vehicle without any porous substrate is less than 7.5 mmH₂O. In one aspect, the porous substrate is retained within the cavity of the delivery vehicle such that the increase in pressure drop across the delivery vehicle relative to the delivery vehicle without any porous substrate is less than 5 mmH₂O.

In this regard, the porous substrate can be retained within the cavity of the housing in various forms so as to minimize the increase in pressure drop. For example, the porous substrate can take the form of pellets.

It will be appreciated that in the above aspects, the delivery vehicle may be supplied with the porous substrate without the formulation specifically impregnated into the porous substrate. Such an arrangement may allow users to functionalize the porous substrate themselves.

Further Aspects

The delivery vehicle of the present invention may comprise a housing or container. In one aspect the housing is adapted to be removably attached to an aerosol delivery device, specifically, at a point along the airflow path of the aerosol delivery device. Furthermore, the present invention further provides a contained delivery vehicle for functionalizing an aerosol, the contained delivery vehicle comprising (a) a housing/container; and (b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w.

As discussed herein, in one aspect the delivery vehicle may contain any of the above carriers as an aerosol forming material. In a further aspect, an aerosol forming material distinct from the delivery vehicle may be provided. Thus, in a further aspect, the present invention further provides an aerosolizable product comprising (a) an aerosol forming material; and (b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w. In this regard, the term “aerosolizable product” refers to a combination of one or more materials, at least one of which is capable of forming a condensation aerosol following heating to an appropriate temperature. Thus, it is not necessary for all components of the aerosolizable product of the present invention to be “aerosolized”.

The present invention further provides a process for forming a functionalized aerosol, the process comprising

(a) providing a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w; and

(b) placing an aerosol in proximity with the delivery vehicle.

The process of the present invention may comprises additional steps either before the steps listed, after the steps listed or between one or more of the steps listed.

The present invention further provides an electronic aerosol provision system comprising:

(a) an aerosol delivery/generation device; and

(b) a delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, wherein the delivery vehicle comprises a porous substrate material comprising at least one porous thermoplastic polymer and at least one formulation held within the thermoplastic polymer, wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w.

In one aspect, the aerosol delivery/generation device has an airflow path along which aerosol generated by the device flows. In one aspect, the delivery vehicle is located in airflow path. In one aspect, the delivery vehicle is located in airflow path such that the aerosol passes through the porous substrate.

The invention will now be described with reference to the following non-limiting example.

Examples

In the present example we utilized Accurel® MP/XP materials which are porous polymers. The MP and XP product lines are manufactured with different cell forming agents resulting in slightly different properties, such as porosity level, additive loading time and loading level. The products can be made using PP, PE, EVA, PS, PET, PA6 PA12, PC, PLA, SAN and PMNA. PVOH versions are also available. The Accurel® porous structure is capable of absorbing high amounts of liquid or low melting point additives. On mixing the additive penetrates the cell structure by capillary action resulting in a free flowing, dry, super concentrate.

Flavor/Fragrance Loading

ACCUREL Microporous Polymer MP100-PP—polypropylene was used in this study.

Sample 1—10 g of Accurel MP100-PP (10 g) was placed into glass jar and 23.1 g of cherry fragrance or menthol added. The glass jar was secured with an aluminium lid on which a spindle had been attached. The spindle was attached to a chuck of a rotary stirrer set horizontally. The jar and contents were gently rolled for 2 hours at 44 rpm (Caframo top stirrer, model BDC50) at room temperature, at which time all the liquid had entered the porous particles, giving a final dry free flowing product which was 70% fragrance/flavor by weight.

Sample 2—the method of preparation of sample 1 was repeated and menthol was replaced with 50% pepermint oil/50% menthol.

Testing

Aliquots (5 g) of the filled particles were then incubated (in triplicate) at the relevant temperature, then weighed at regular intervals for an initial period of 24 hours. The weight loss was calculated and plotted against time. Control flavor particles were incubated alongside the menthol/cherry loaded particles for comparison. The control sample at 20° C., 40° C., 60° C., 80° C. and 100° C. is shown in FIG. 1. Sample 1 at 20° C., 40° C., 60° C., 80° C. and 100° C. is shown in FIG. 2. Sample 2 at 20° C., 40° C., 60° C., 80° C. and 100° C. is shown in FIG. 2.

Within the 24 hour period the weight loss from the Accurel was approaching 70% for both the cherry fragrance and for the peppermint/menthol. The hump noted at 100° C. around hour 15-20 is related to the plot program and not an actual result.

It was found that the loading achieved was very high. At elevated temperatures the porous materials do not hold onto the ingredients particularly well. However, at moderate temperatures, such as those at which the products are typically stored, the loss over time was modest.

The thermoplastic polymer used in the present example was identified as being a very good material for producing a highly concentrated free flowing substrate containing a liquid flavor.

Pressure Drop Investigations

In order to test the impact of the delivery vehicle on the pressure drop across an aerosol delivery device, the following experiment was conducted.

An aerosol delivery device available from British American Tobacco (eTank Pro, www.govype.com) was used to assess the impact of the delivery vehicle comprising the functionalized porous substrate on the pressure drop across a typical device. The eTank Pro device has a detachable drip-tip (mouthpiece) and so it is possible to replace this with the delivery vehicle of the present invention.

The delivery vehicle used in the example comprised Accurel MP100-PP (hemi-cylindrical prism pellets of approximately 2.75 mm by 2.89 mm by 1.69 mm, the pellets having an average mass of 34.40 mg per pellet, based on the mass of 32 pellets. 15 to 20 pellets were loaded into a delivery vehicle mouthpiece sized similarly to the mouthpiece of eTankPro. The cylindrical cavity of the mouthpiece within which the pellets were held had a total volume of 655 mm³. For comparison purposes, the same delivery vehicle mouthpiece was used without the porous substrate and with cellulose acetate in place of the porous substrate.

TABLE 1 Pressure Drop # Configuration (mmH2O) 1 eTank Pro (with mouthpiece) 46 2 etank Pro mouthpiece alone 0 3 Delivery vehicle mouthpiece alone 0 (no porous substrate) 4 etank Pro + Delivery vehicle 46 mouthpiece (no porous substrate) 5 eTank Pro + Delivery vehicle 48 mouthpiece (with porous substrate) 6 Delivery vehicle mouthpiece (with 2 to 3 porous substrate) 7 Delivery vehicle mouthpiece (with 26-27 cellulose acetate) 8 eTank Pro + Delivery vehicle 75-76 mouthpiece (with cellulose acetate)

As can be seen from Table 1, when a delivery vehicle including a porous substrate comprising at least one porous thermoplastic polymer having a formulation loading capacity of at least 30% w/w is used, the impact on pressure drop across the device is far less pronounced than when the same delivery vehicle mouthpiece comprising cellulose acetate is used. This is an advantage because the user will not notice a significant change (if any) in the pressure drop across the device when using the delivery vehicle according to the present invention. On the other hand, due to the porous nature of the thermoplastic polymer, it is possible to load relatively high amounts of formulation onto the porous substrate, thereby leading to an appreciable functionalization of the aerosol as it passes through the delivery vehicle.

Various modifications and variations of the present invention will be apparent to those skilled in the art without departing from the scope and spirit of the invention. Although the invention has been described in connection with specific preferred embodiments, it should be understood that the invention as claimed should not be unduly limited to such specific embodiments. Indeed, various modifications of the described modes for carrying out the invention which are obvious to those skilled in chemistry or related fields are intended to be within the scope of the following claims. 

1. A delivery vehicle for functionalizing an aerosol in proximity to the delivery vehicle, the delivery vehicle comprising: a porous substrate material comprising at least one porous thermoplastic polymer; and at least one formulation held within the thermoplastic polymer; wherein the formulation comprises at least one functionalizing component and the porous thermoplastic polymer has a formulation loading capacity of at least 30% w/w based on the porous substrate material.
 2. The delivery vehicle according to claim 1, wherein the porous substrate material is contained in a housing.
 3. The delivery vehicle according to claim 2, wherein the housing is adapted to be removably attached to an aerosol delivery device.
 4. The delivery vehicle according to claim 1, wherein the at least one functionalizing component is at least one flavor component.
 5. The delivery vehicle according to claim 4, wherein the at least one flavor component is selected from the group consisting of (4-(para-)methoxyphenyl)-2-butanone, vanillin, γ-undecalactone, menthone, 5-propenyl guaethol, menthol, para-mentha-8-thiol-3-one and mixtures thereof.
 6. The delivery vehicle according to claim 5, wherein the at least one flavor component is at least menthol.
 7. The delivery vehicle according to claim 1, wherein the at least one functionalizing component is present in a total amount of at least 50 wt. % based on the at least one formulation.
 8. The delivery vehicle according to claim 1, wherein the at least one functionalizing component is present in a total amount of at least 70 wt. % based on the at least one formulation.
 9. The delivery vehicle according to claim 1, wherein the formulation loading capacity is at least 50% w/w based on the porous substrate material.
 10. The delivery vehicle according to claim 1, wherein the formulation loading capacity is at least 70% w/w based on the porous substrate material.
 11. The delivery vehicle according to claim 1, wherein the at least one porous thermoplastic polymer is selected from acrylonitrile butadiene styrene, natural rubber, nylon 6, polyamide, polyamideimide, polyarylate, polycarbonate, polydimethyl siloxane, polyetheretherketone, polyetherimide, polyethersulphone, polyethylene, polyethylene terephthalate, polymethylmethacrylate, polyoxymethylene, polyphenylene sulphide, polypropylene, polystyrene, polysulphone, polytetrafluoroethylene, polyvinylchloride, and mixtures thereof.
 12. The delivery vehicle according to claim 1, wherein the at least one porous thermoplastic polymer is at least polypropylene.
 13. The delivery vehicle according to claim 1, wherein the at least one porous thermoplastic polymer comprises a first porous thermoplastic polymer and a second porous thermoplastic polymer, wherein the first porous thermoplastic polymer and the second porous thermoplastic polymer are different from each other.
 14. The delivery vehicle according to claim 1, wherein the functionalizing component is a solid at a temperature of 40° C.
 15. The delivery vehicle according to claim 1, wherein the functionalizing component is a solid at a temperature of 60° C.
 16. The delivery vehicle according to claim 1, wherein the functionalizing component is a powder.
 17. The delivery vehicle according to claim 16, wherein the powder is a free flowing powder.
 18. The delivery vehicle according to claim 1, further comprising a carrier.
 19. The delivery vehicle according to claim 18, wherein the carrier is selected from water, glycerol, propylene glycol and mixtures thereof. 20-21. (canceled)
 22. The delivery vehicle according to claim 1, further comprising an active agent.
 23. The delivery vehicle according to claim 22, wherein the active agent is at least nicotine. 24-25. (canceled) 